Model development for layer-by-layer determination of the fiber volume content in fiber-wound high-performance pressure vessels for hydrogen storage

Master thesis

Tank winding is a key technology for modern high-pressure tanks, especially for hydrogen storage applications. For this purpose, carbon or glass fibers soaked in resin are wound around a core (liner) with different orientations in order to withstand pressures of over 1200 bar. Hydrogen is a key element in Germany’s climate-neutral transformation by 2045 in various sectors such as the steel and chemical industries, the transport sector, energy supply and heat supply for buildings.

© IKV

A decisive parameter that determines the mechanical performance of the pressure vessel is the so-called fiber volume content. This reflects the volume ratio between fiber and resin. The winding and curing process influences this parameter through various physical phenomena, which are to be represented in a model. A thermomechanical model for calculating the fiber volume content has already been established. However, the experimental data show different characteristics that are not currently represented by the model. The aim of the work is to extend the existing model on the basis of further experimental data and to enable a meaningful calculation of the fiber volume content. The initial aim is to develop a test method that can be used to clearly quantify and compare the fiber volume content of the individual winding layers. The model is then expanded on the basis of the representative data obtained.

Objective:

The aim of the work is to develop a thermomechanical model for calculating the fiber volume content in wound high-pressure tanks. A suitable test methodology is to be developed for this purpose, which generates representative experimental data and is used for modeling. This should enable a more precise and layer-by-layer calculation of the fiber volume content in order to improve model accuracy and more realistically represent physical phenomena during the winding and curing process.

Your task:

You will work on the following tasks for a Master’s thesis:

• Robot-based winding of representative hydrogen tanks
• Development of a test setup for measuring the fiber volume content for the winding and curing process
• Correlation of the determined data with the existing model and extension of the fiber volume content calculation

Your profile

• Preferred study programs
  • Mechanical engineering / industrial engineering, specialising in mechanical engineering
  • Computational Engineering Science (CES)
  • Simulation Sciences
  • Materials science